Processes for preparing decorative surface coverings



PROCESSES Fon nner-t sorua/sca c o rnnfzonarrw tives l Joseph.. C. Hurkins, Jr., Kennett-Square, and Frank E'.

Ehrenfeld, JHx'.,v Brookhaven, Pa., and Robert J. Eir'zel, Wilmington, Del., assignors to Congoleum-Nairn Inc., Kearny, NJ., a corporation of New York Ified lct. 29, 1963. Ser. No. 319,879 7 Claims. (Cl, 156-79) This inventionrelates to flexible, 'compositionV qmrfaee coverings and particularly to `'plast-ic surface coverings;

having a wear layer containing decorative chips and par ticularly to processes for preparing such surface coverings.- t

ln aocondance with present commercial practice, plastic surface coverings comprise synthetic or natural thermoplastic tesinous binders, pigments, stabilizers, illers and the like. They are prepared in sheet or tile. form and 'widely used as coverings forv oors, Walls, counter tops,-

vehicle interiors and the like. Such products usually range inthickness from about 0.015 inch to 0,'12'5 inch and are often secured to backingstof felted-fibrous sheets impregnated with water-resistant', strengthening impregnants.

in the binder of plastic sunface coverings. Polyvinyl Vinyl resins are most commonly employed as the resin the streaks to form a decoration simulating the graining they become'em'bedded in thel composition sheet. v products ust; ally depend on the hardness of thedecorative placed in overlapping relationship and fed to a second calender operation. ThisV second calendcringbreaks up in marble. This process is more fully described in U.Sr Patent 2,917,781, issued December 22, 1959, to Robert K.

Petry. v

Variegated color effects likewise have been .produced by initially forming by passage between rolls a sheet having substantially uniform color throughout and prior to 'further formation of the finished sheet by passage between additional rolls adding pieces of contrasting color which may be-oi the character aforesaid, so that, upon being subjected to` calendcring with the initially formedfsheet, Such pieces and the plasticity of the sheet tor become embedded in tbc sheet with only .limited distortion. Such a procechloride, including its copolymers and terpolymers, and y particularly polyvinyl chloride copolymerizedv with vinyl` acetate,v are used in the greatest quantities Plmticizcrs are normally added to the resinv to make up the binder to give iiexibility to the composition. composition is prepared by mixing all of the ingredients of the composition under conditions of high heat and pressure in a mixing device such as 4a Banbury mixer. During the mixing the thermoplastic resinV is solvated and fused by the plasticizer to form the binder which holds vthe fillers and pigments in a homogeneous composition.

After mixing, the composition is formed into a sheet by passing it through 'heated calender rolls'. The calender rolls are usually heated to between 200 to 350 F., whichi: above the softening temperatures of the composition. A

solid colored sheet is obtained in this-manner, which, after cooling, is suitable for use as a surface covering.

Most products of the type pmducec., however, have a variegated a'p;r carancf` and, therefore, are more decora,-

tive and pleasing lo the eye. Vanegated sheets are obtained by comminuting a number of dilerently colored plain sheets and mixing the discrete granules so obtained in me desired relative ccor proportions. The mixture,

.while heated to a plastic and moldable consistance, is

consolidated by one or more calend'ering'` operations at the aforementioned @cycled temperatures. ln the calenderiug, the individual granules largely retain their ndividual colors, but are subject to substantial distortion-al connninglng. This distortion commingling is evidenced in `the product of the` first calendering by the"fact that` the granules have, become distorted into long streaks to provide a striated ellect that is commonly known as "jaspe. In. addition to the jaspe el'l'ect, a simu-latedV marble effect can be produce-dbyfurther dist'ortionaly cornmingling of the granules of dilferent color, This is usual. lyc scm-ted above are cut at intenvahi,y 90 degrees,

By this method, yjaspe sheets prepared as der `v Conventionally, the

' smooth surface covering o1' plastic composition having an Adure is disclosed' in U.S. Patent 2,888,975, issued lune 2, i959, to Walter E. Benedict.

These calender-ing operations produce products having at least some degree of directional characteristics. By directional characteristics, it is meant that it is readily apparent by an unskilled eye which direction the product was calendered since the decoration is more or less distorted in the direction of ealendering. Many attemp ts have been made to produce overall, non-directional decorations by means of continuous calendering equipment.` Completely non-directional decorations have only been obtained by pressing and molding operations whereby granules of resinous con'ipositions are spread in a press and forced into a compact, uniform sheet by pressure exerted .in one direction on thc surface of the granules. ln such a system, under suitable conditions and temperature, the. particles remain substantially undistorted in shape. These products are commonly referred to as having a terrazzo type decoration in that they are composed of distinct, non-directional areas of contrastingcoloration. Such intermittent molding operations are substantially slower than the continuous calendering system and, therefore, the product produced has a premium price.

An object of the invention is to produce a tiexible,

overall, non-directional decoration in a simple and' economica-l manner. Another object of the invention is to provide a process for producing such a product capat,L t

of adaptation to continuous high speed operations. A .further object is to provide a process for producing a plas- Y tic composition sheet `composed of synthetic resinous 'amplis-hed by the soscalled. crosscaienderingjteclp compositionk having unique structural characteristicsand an exceptionally smooth and attractive decorative appearance. Other objects of the invention relative to the provision ot an improved method for making a plastic composition sheet of synthetic resiuous composition having areas of contrasting color whereby sharply defined, predetermined boundaries between the areas of dilerent color produced.v Additional objects andthe advantages of thev invention will `be apparentv lfrom the following description.

' lnaccordance with the invention, a exible, smoothsurfacetloof covering having an overall, non-directional decoration is produced by depositing on a weby a uniform layer of a liquid rcsinous composition, depositing on the.

liquidv coating, colored granules of compatible resinous plastic' composition, heating the coating and granules to fuse the composition andsubjectiug the. heated granules to Patented August 9, 15966 seams-4e @a planisliinfg operation betweenA rolls maintained at tem pcraturessubstantially below thc fusion temperature of the temperature of the composition which exerts sufficient pressure to smooth the surface of the sheet without sub stantially distorting tbe shape of the granules. The prod'- uctcan tlie-n. be subjectedto other conventional finishing operations such as embossingcutting, or the like.v

Alternately, if the web is a release paper, after cooling the sheet formed' from the fused coating and chips can be stripped from the paper. The sheet can then be used as such -or laminated to any desired backing. Either f side of the sheet can be used as t-he surface. As a general rule, the smoothest surface is the side which contacted the release paper. A particularly desirable product con be obtained by laminating the stripped sheet to the surface of a foamed or foamabe layer of resinous comv position. This can be readily accomplished by the use of an adhesive if a prefoamed l-yer isused or by fusing and foaming the layer in the saine operation as the chipcontaining layer is fused.

In accordance: wit-h the invention, it is possible to produce anotfcrall, non-directional decoration in plastic composition sheets by high speedv coatitts; procedures. Such i aresult was heretofore unobtainable, since the direct calendering of granules of plastic composition together to form a sheet would restntin their elongation and/or streaking with substantially complete loss of their individual characteristics.

' The invention will be better understood from the following detailed. description when read in coniunctionwitli product;

FIGURE 5 is a plan view of the finished product shown in FIGURE 4; y

FIGURE 6 is a schematic representation of a second embodiment of the invention; t

FIGURE 7 is a cross-sectional view of theproduct at an intermediate stage taken along line 7-7 in FIG- URE 6;

FIGURE 8 is a cross-sectional view of the product at an intermediate stag-c alien along line 8 8 in FIGURE 6; and

FIGURE 9 is a cross-sectional view of the finished product produced by the process illustrated in FIGURE E. Referring to the drawings, a web of backing material 11 issuppiicd from supply roll 12 and passes to a coating feeder has a hopper 2.1 for holdingtl'te granuleszti allowing a uniform flow onto an inclined vibrating plate 22:

which applies an even layer ontotii: coated web'13. The

granules can be applied so that they are in spaced relationVVV on the surface of the eoatedwe'bor can' he closely packed together. As a gis-:nerali rul'e, tliecovcregek of the' web bythe granules should be less than 100%. The layer of f granules is carried by the web toa heating device, -gcnerally indicated at 30, 'such as a hank'o infra-red heat lamps or forced hot air, to; raise the temperature of the compositions. The exact temperature toA whichthegranules and coating areheat'ed' willl depend onfthe particular compositions utilized, but as ageneral rule, a temperature apparatus generally indi filed at i3'. The coating appr-.-

ratusshown is a reverse roll coater, but any type of coating apparatus can be used'. The reverse roll coater comprises an applicator roll i4, a smaller roll 15 l:ontacting the applicator roll and a back-up roll 16 which presses the web 11 against the applicator roll 14. A liquid resinous composition 17 is fed to the nip formed by the applicator roll 14 and the small roll 1S. The small roll applies a smooth coating of the resinous composition 17 on the surface of the applicator roll 141. The coating on the applicator roll is transferred` to the surface of the web as it contacts kthe applicator roll 14. The coated web 18- is passedv under a feeding. mechanism generally indicatedat 19 which appl-ies a uniform layer of plastic com.-

position granules 20 to the surface of the web. The feeding mechanism can be any apparatus which is capable of' applying a uniform layer of granules to the web. A. vibrating feeder, such as those known as the Syntron type. which have a vibrating ineline'djpla-te over which the granules move has proven particularly elective. The

of from about 325 to aboutl 400 F. is!required.4 The oven is generally at a h-ighertemperature than that reached by the composition. The length of time required' in the l oven will depend on the rate of -heat transfer but as a f general rule from two to ve minutes` issufficient. The

heat is preferably only supplied to the upper surface toy prevent the web from being heated to above its deterorav tion temperature.

The weight of the granules will cause them to sink into the coating. This rate will vary and depending on the time fusion takes place the granules can be at various les'- els. The penetration of the granules into the coating will also depend on the viscosity of the coating. If the viscosity is relativelyhigh the lgranules will remain on the surface only partially submerged in the coating. Planish. ing will force the granules into the coating composition.

In this latter procedureA the `surface of theV granuleswill.

all be' at approximately the same level. The amount of pressure applied by the planisher can be regulated to con.- trol the texture of the surface of the finished sheet.

The heated granules and coating can then beconvcyc-.dAv

by the web to a planishing unit, generally indicated at The plnnishing unit is made up of a large diameter hard surface roll 36 and a small rubber-covered back-up roll 37. The larger roll 36 presents a smooth, rigid surface suitable for imparting the desired finish' tc the composi tion sheet. Thus, the roll can have a ehromfanish or i it can he a polished steel roll. If a surface finish or' some other type, such as a matte finish or embossed surface is desired, then the surface of the roll can be appropriate for the production of such a finish. Roll 37 is provided with a surface `layer 38 of yieldable, resilient material.

For example, the layer 38 o n the surface of vthe roll 37 can be about l'inch in thickness ofsome material' which will withstand heat. A synthetic rubber material, such as chlorodibutylcne polymer or butadiene and styrene copolymer, is suitable for the purpose. Both rolt's 35 and 37 preferably have means for circulating a cooling fluid" there-through to maintain their temperature. kThe rubber covered roll is usual-ly maintained at about (D to 1:'0" F. The larger roll 36 is maintained at a temperature substantially below thc temperature` of the granules and will,

therefore, present a relatively cold surface to the, heated l granules. As general rule, itis preferred for this' roll to have a tempera-iure at least 75 F. below the fusion temperature of the composition.v The pressure-exerted by the top roll .36 should be just sufficient to consolidate the granules into a: smooth uniform sheet without distorting their shape. The pressure` applied between the rolls will depend to a great extent upon.l the components of the composition. The maximum" pressure allowable for a particular composition can be readily. determined by utiltzing a small .test sample. As a general rule, the pressure should be less than G'pounds per square inclrsince" y above this pressure, the rcsilient-eovered back-up rollV willV v deteriorate. Pressures of from about 5() pounds to'aboutl 300 pounds per square inch have been found particularly l efective. The back roll 37 ismaintainedf at a temperature low enough to prevent damage to the felt. sheet is preferably allowed to adhere and 'he carried' by f 'i the .forger roll for par! of itsy revolution and theirstripped` f from the roll by a stripping rol-H9. The sheetv on. leaving 5* i the planishing unit' is passed over cooling drums-i0, and 42, and wound on a collecting roll 43. Y

The product produced: has a smooth decorative surface y made up of the granules which are substantially undistorted in appearance. The liquid coat-ing lls the area between the chips thereby holding the sheet together in a uniform mass. r

An alternate method is ducing a product having arvinyl composition foam Yintermediate layer. The steps shown in FIGURE 1 are fol-y lowed, except that web 11 is a release paperV 6ta'. Thefuscd con'iposition is fed from the. planishe: genermiy indicated at 35 over the cooling rollsv` 40', 41 and 42- to al stripping apparatus, generally indicated at 50. The strip ping apparatus comprises two rolls 511' and 52. The composition layer 53 comprising the granules and liquid coat-` iing in a fused condition isiallowed to follow the top roll' Sl and is fed to laminating rolls, generally indicated at 55. The release paper et) is allowed to follow theopposite roll 52 and is thereby stripped from the back lof the sheet. The release paper can be reused a number of times.

The sheet which is laminated to the composition strippe from the release paper is formed by feeding a backing web '70 from a supply roll 7l to a coating apparatus, generally indicated at 72.

coating to tlc surface of a moving web. A reverse roll conter is illustrated which comprises a large coating roll 73 which applies the coating composition 74 tothe sur# face of the web 70. The composition 74 is supnlied from a reservoir of the composition contained in the nip formed by the large roll .3 and a small roll 75 wl "ch presses The web 70 is forced against the against the large roll. coating roll 73 by a pressure roll 76. In this embodiment,

a resinou'; composition is applied to the surface of thel web containingy a blowing agent which upon heating will decompose to form a' foam structure in the coating com-k position 74. The coated web 77.1Eten passes through an oven, generally indicated at 73, which heats the composition to fusion temperature and decomposes the blowing agent to form a cellular foam coating.v The fozimed coated web S0 is then passed over cooling rollsl, 82 and The coating apparatus can be any conventional coating machine capable of applying athin able composition is applied directly to tbc resinous layer supported -on' release paper en -passed through. an oven to decompose 'the blowing. agent. and' foam the coating.

' UtilizingV such` a process it is preferable that the resinous layer be only partial-ly fused initially the rr-:onplete fusion take place with the fusion of the foamable layer. lfY desired, an adhesive can then: be applied to tbe eellulose `foam layer and n ooring felt orother backingv laminated tothe exposed surface of the foam layera Another embodiment of the invention involves the formation of' al product wherein the chips are oriented in- I' closelypacked, side-by-side relationship. This can he accomplished by applying a heat-activated adhesive to a backingA web, andv then distributing chips on the adhesivecoated web. The web is vibrated, if desired, toorient the chips. The sheet is then heated to activate the adhesive and the chips pressed tol the activated adhesive.l Any chips which do not .adhere to the surface can be removed by inverting the sheet. A plastisol or organosol is then coated on the surfaceof a release paper andthe wet surv face brought in contact with the chipcover..d sheet. The

composite sheet is then heated to fuse the composition,

,then planished,` then the release paper removed and the surface of thc sheet pressed or planishc'd to smooth the surface it desired; As a further alternate a thin transparent film can be laminated to the surface o the product. Such films can vary from less than @.901 inch in thickness up to about 0.010 inch.

83. The cooled sheet passes through an adhesive coating apparatus, ger'crally indicated at 84. The apparatus comprises a coating roll 85 which places a thin layer of adhesive on the surface of the foam sheet. The adhesive is supplied to the roll from n reservoir 86 held in Contact with the roll. the foam layer 80 against the adhesive-applying roll 85.

The adhesive-coated foam sheet 88 is then passed through a tivo-roll luminator, generally indicated at 55, where it is laminatedto sheet 53. Any of the conventionally used adhesives for securing vinyl sheets together can he utilized.

The laminated product 89 is then wound on a collecting roll 90. As an alternate procedure, the release paper 60 can be removed after lamination to the foam layer. The product has a felt backing, an intermediate cellular foam layer and a decorativewear layer. As illustrated,

the side of the decorative layer in Contact with the release paper is used as the surface of the product. Alternately, the opposite side can be used as the surface ofthe product.. Additionally, tlte sin face can have a texture by eliminating the planishing or utilizing an engraved embossing roll' instead of the conventional smooth roll` or' the planisher.

As indicated in another embodiment of theV invention,

the foamable composition can only be heated to partial-v ly .inse the composition and the sheet brought inV Contact` with the coated web which is also only partially fused.

The composite structure is thenheated to fuse: thecom;

A small pressure roll 87 forces dered or pressed tc form a flexible sheet can be used to forrnbaclcing sheets which can be used in the invention.

' can be compounded with plasticizers and fillers andy rvarious synthetic fibers.

i wound rolls and must be capable of being rolled and unrolled without cracking or tearing. Strength is important in a backing in view' of the strains 'to which the product is subjected when handled both during mzmuf'acturev and immediately prior to installation.

Suitable backing sheets include those formed of flexible resinous composition as well as sheets of woven fabric and impregnated felted fibers Any of the thermoplastic or elastomer resinous compositions which. can be calen- Suchresins as copolymers of butadiene and styrene, polymerized chloroprene, polyvinyl chloride, vinyl chloridevinyl acetate copolymers, polyvinyl acetate, and the like sheeted to form a flexible. sheet. I-n some cases, scrap and' degraded resinous'. compositions can be salvaged by form'- ingrthem into sheets which. can be used as backing sheets in producing. products in accordance with the invention.

As indicated, suitable backing sheets also include woven fabrics formed of such fibers as cotton, wool and Where loosely woven fabrics such4 as burlap aroused, the fabric can Le sizedA to prey vent passage of the printing composition through the fibrous. sheets impregnated with a water-resistant and`v strengthening impregnant yield desirable backing sheets v forthe production of products in accordance with the inpositions andeecompcse the blow-ing agentk in the foam-- i able composition. The temperature required for partial strong.- Thev sources of cellulose cany inclue-.c other rags, lwood pulp, paper boxes or mixtures thereof openings between the fibers.

It hasv been found. that felled cellulose orv asbestos vention since theyare low in' cost and yet are tiexible and "e cotton or in any proportion.y In addition', llers such as wood flour i een be usei'l The felt sheet is formed from a slurry of fusion will depend on the composition. As. :a5-general rule, a temperature of about 50 F. to 1501 F. below the fusion temperaturey isadequate. Alternately foam.-

rc'as material nwate'r using any of the techniques eonveationally'employed in the manufacture. of paper. For example, sheet formulation can taire placev on a.:

Fcurd'rinier loricylinfzler sheet-forming machine. The

i fibrous sheet soprepa-red is then dried. In addition to cellulose and asbestos, other fibers can be used "including synthetic-fibers ari-these of. mi ral-and animal origin.

The particular inipregnant'gchosen must not` only lbe capable of imparting strength and water resistance to the sheet of felled fibers, but must also. meet other'requirements as to its physical and'chemical behavior at the processing;l conditions utilized The coating;y compositionk 'applied 101th.: backing in accordance with the invention must be heat-:d to temperatures a: high as 300 to ,400 F.

in order to fuse the resin.- Thus, if the impregnated bac.

ini; web is part of the product at this stage the impregnant chosen must be stable at thesetcmperaturcs. The impregnant should be substantially free oi any components which are volatile at these temperatures and it also most not soften toi-such an extent as tol exude from the sheet.

i limited to the application of a thin. layer of about 4 to SV n mils in thickness. lf'a thicker layer is required successive .v

la addition, the satur'ant should not be subject to appreciable detrimental chemical changes such as oxidation.

Asphalt impregnated felt can be'uscd. as-a backing sheet in the invention but when it is to be subjected to. high.

' acrylic acids and their polymerized derivatives, polyethylene, polystyrene, butadiene-styrene copolymer, butadieneacrylonitrile copolymer, natural rubber. polymerized chloroprenc and t'te like. Thermosetting resins which under the influence of heat cure by polymerizing and crosslinking can also oe used as impregnants. Such resins as phenolic resins, pvesters, oleoresins such as drying oils and the like, isoey nales and polyurethanes and the like are suitable. I

Some resin impregnants which pro luce a felted sheet with excellent physical propertfes are not compatible with the resinous composition to he applied and result in poor adhesion ofthe compositionto the felt. In such cases, it is desirable to size the surface of the impregnated felt sheet to which the composition is to be applied with a thin coating of material which hasV good adhesion to both the .felt impregnant and the resinous composition. Where a pl'asticized polyvinyl'chloride polymer is used, excellent results have been obtained over a wide variety of feit impregnantsusing a size of acrylic polymer latex. A mixture of equal parts of a soft acrylic poly nier latex and a hard acrylic polymer latex has been'found particularly effective in aiding adhesion, without. causing sticking of the sitedl surface to the rolls during processing; The sizc coating is etlective in small amounts, an application otY i only 0.02 pound dry weight per square yard being auth-- cient to obtain une improvements. Other material-s can be similarly 3.1:. l, pregnant arti' r tot composition applied' thereon. A butadiene-aow ..itriie polymer latex either alone or vin combination .51h hard acrylic resin emulsion effective.

The resinous binder utilized for the coating compositions andA granules must be one that is coal'esced or fused. into an elastomeric composition by they application of heat. The dispersion medium can be water inthe case of an aqueous latetoanl organic solvent, or a fluid plasticizer for the resin used.. Ay dispersion ofresin in plasticizer polymerized therewith.

. mot-.omer is Copolymerized therein.

' in size.

to remove the carrier as is necessary with water and organic solvent carriers. The use of organosolsis usually organosol layers are usual-lyv applied.

The preferred andmost widely used resins for surfaces' coverings are polymers of vinyl chloride.` Thevinyl chloride polymers can either be simple, unmixcd homopolymers of vinyl chloride or copolymers, terpolymers or the;y

like thereof in which the essential polymeric structure of polyvinyl chloride is interspersedat intervals with thev .residues of other ethylenically unsaturated compounds The essential propertiesof the polymeric structure of polyvinyl chloride will be' retained if not more than 40 percent of the extraneous ce,-

Suitablc extraneous co-monomers include, for instance, vinyl esters on the order of' vinyl bromide, vinyl fluoride, vinyl acetate, vinyl chloroacetate, vinyl butyrate, other tatty acid vinyl esters, vinyl alkyl sulfonates, t-richlorethylene and the. like; vinyl ethers Stich as vinyl ethyl ether, vinyl isopropyl other, vinyl chlorethyl ether andthe likegcyclic unsaturated compounds such as styrene, the mono and polychlorostyrenes, coumarone, indette, vinyl ftaphthalenes, vinylA like; acrylic acid and itsv Y, derivatives such :is ethyl acryinte, methyl rncthacrylate, ethyl chloroacrylate, acrylonitrile, methacrylonitrile, di-

t... im.;

pyridines, vinyl pyrrole anu' ethyl malente, dicthyl fumaratr and the. like; vinylidene compounds on the order of vinylitienc. chloride', vinylidene bromide, viuyl'idene .fiuorocnloridc and the like;

unsaturated hydrocarbons Vsuch as ethylene, propylene,

isobutene and the like; allyl compounds such as ally! ace- 1 tate, allyl chloride, allyl ethyl ether and the like; and conjugated and cross-conjugated etbyenically unsaturated'y compounds such as butadiene, isoprene, chloroprene, 2,3- dimethylbutadienel,3, pipcrylene, divinyl ketone and the like. l

Resins adaptablel for use in formulating vinyl lplastisols are commonly referred to as dispersion grade resins. Suchresins are available having particle sizes of from 0.02 to about 2 microns in contrast to calender grade vinyl resins which are available in particles ranging up to microns molecular weight than calender grade resins particle surfaces of a hard, horny nature.

Polymers ofvinyl chloride having specitlc viscosities above about 0.17 and preferably between 0.17 and 0.31

, as measured in a solution of 0.2 gram of resin in 100l depending upon the type of felt im-v f is conventionally'termed a-plast-sol, and adispc .Psion in an organic solvent an orgsnosol. Pl-astisol's and organosols.

have appreciableA fluidity at normal room temperature but are. converted ly heat intot. flexible', tough thermoplastic I mass. 'lhisultintate result i; brought-aboutby the process of rfusion wherein ,the resin. becomespl asticfized and' comv pletely solvate'd by the plasticizer. Plastisols are preferred for the oamahlelcomposition since it is unnecessasy milliliters of nitrobenzene at 20 C. are particularly effective. in the determination of specific viscosities, the sample of resin in nitrobenzene solutions maintained' at a. temperature of 20 C. is allowed to tlow between two calibrated marks in a pipette and time requiredpis recorded. This time is compared with the time required lfor a control o? pure nitrobenzene solven: o pass between the same twomarks, also at a temperature of 20 C.v The specitlc viscosity is determined as the sample flow time The specific divided by the control ov.' time` minus l. viscosity'is an effective measure of relative molecular weight of the polymer, the higher the specific viscosity `the higher being the molecular weight.

In the formulation of coating composition for use in the invention, the resin is uniformly dispersedl in amass of uid plastic'izer in a plastisol or with plasticizer and:

organic solvent with an organosol. The liuidity of plasti- Y.

sols is inuenc'cd in part by u1:- narticular resin selected but is also a function of the ratio of plasticizer to resin. v`

Plastsols become less fluid as the ratio of plasticiner to resin is reduced. Coating compositions for use in the in vention contain from about to about 15'0 parts plasticizcr per 100 parts resin with a range of aboutftll to about 100 parts plasticizer per 100 parts resin being particularly etieetive.` With organosols, the plastieken Y' level can be as lowas 20 per 100 parts of resin upl to about..

parts with 30 to 40 parts of plasticizer per' 10@ parts; t

Dispersion grade resins are usually of higher and have,

of resin being preferred;

per i() parts resin are used.

The viscosity of the compositions can be reduced by the addition of a volatile dil'ucnt.

agences..

Pla'stisols usually contain less than l0 parts of dil'uent perVV f 100 parte resin. T lseful dilnent include henmne, toluene,

methyl ethylketonc, petroleum solvents such as Virt. andl P. Naphtha (boiling range oi i90-275 F.) and the like. Suitable coating com positions'havc a viscosity at 25 C. o

from about 200. to about 25,000 ccntiposes as measured-l with a Brookfield RVF viscomcter using a No. 3 spindle at 2 r.p.m l

The selection of the plasticizer is important in etere minirm the strength and cxi'bility of the coating and also in influencing the viscosity, stain resistance and the foaming characteristics of the composition. Esters of straight and branched chain 'alcohols with aliphatic acids impar: low viscosity and good viscosity stability.

Typical plasticizers of this type include dibutylsebacate, dioctyl sebacate, dioctyl adipate, didecyl adipate. dioctyl azelate, tricthylene glycol di (2-ctiiylnexanoate), diethylene glycol dipclar-gonate, triethylcne glycol dicarprylate and the like. Plastic'izers of the aromatic type, such as esters of aliphatic alcohols and aromaticl alcohols and aliphatic acids or aromatic alcohols and aromatic acids are desirable. The use of highly aromatic plasticizers is limited, by their tendencyl to yield plastisols of Vhigh viscosity.

Typical plasticizers of thi-s type include :iibutyl phthalate, dcarpryl phthalate, dioctyi phthalate,

dibutox'y ethyl phthalate, dipropylene glycol dibenzoatc,

butyl benzyl sebacate, butylbenzyl phthalate, dibenzyl sebacate, dibcnzyl. phthalate and the like. Other types of plasticizers, such as esters of inorganic acids, including tricresyl phosphate, octyl diplzcnyl phosphate and the like, alkyd derivatives of rosin, chlorinate paraflne -high molecular weight hydrocarbon condensates andthe like can also be used. The piasticizer or blend of plasticizers is chosen to yield a composition of t'ne desired viscosity and/or foaming characteristics. In addition, the plasticizer should preferably have a low vapor pressure at the temperatures required to fuse the resin. A vapor pressure of two millimeters of mercury or less at 400 F. is satisfactory.

Minor amounts of stabilizers are usually incorporated in the coating compositions to reduce the effects of de gradation by light and heat. Suitable light stabilizers include resorcinol disalicylate, resorcinol dibcnzoate, phenyl phthalate, phenyl benzoate, o-tolyl benzoate, eugenol, guaiacol, o-ntrophenol, o-nitraniline, triet-hylene glycol salicylate, and organic phosphates and other cornplexes of such metals as barium, cadmium, strontium, lead,tin and the like. Suitable heat stabilizers include sulfides and sultes of aluminum, silver, calcium, cadmium, magnesium, cerium, sodium, strontium and the like, glyeerine, leucine, alanine, oand p-amino benzoic and sulanilic acids, hermmethylene tetramine, weak acid radicals including oleatcs, recinoleates, abietates, salicylazes and the like. Normally, the compositions contain about 0.5 to about 5 parts stabilizer per 10.0v parts resin. 1

The compositions can be transparent cr contain pigments in accordance with the particular color desired. Any of the organic. and inorganic pigments vfcll-konwn in `the art for pigmenting compositions can be used. Normally, from about 0.5 to about 6 parts pigments The foainable compositions contain, in addition to the otheringredients, an effective amount of blowing agent. The larger the amount of blowing agent withinpractieal limits used the greater is the expansion of the foam. Foam densities of from 10 percent to 50 percent of the density of the unblown composition can be readily attained. Such. results are attainable with from about l to about parts blowing argent per 100 parts'resin. About 2 to 10' pans blowing agent per 10i) part-s resin is particularly effective for the production of foams` of a density which are most desirable for use in produc-ing surface coverings in tion;

accordancev with Complex organic compounds which, when heated, de compose to yield an inert gas andhave residues which are compatible with the resin usedl in the compositions yieldV an inert gas high in nitrogen. Typical compounds include.` substitut-:d nitrose compounds,V substituted hydrazides, substituted axo compounds and the like, such as .are tabulated below:

Blowing agent: y Decomposition temp. Dinitrnsopentamethylenetetramine `355--375 F.

Azodiformamide (1,1' azobisforrnamide) B-400 r. p,p'0xytiis tbenzen suifonyl hydra'- zidc) G-340 F. Azobisisobutyronitrile v 220-250 F. N,N dimethyl N,N dinitrosotere phthalarnide i90-300 F.

The decomposition temperature depends in large measure on the particular composition. Catalyst can be added to aid in the decomposition and change the temperature range.

An etiective amount cf blowingagcnts for use in the invent-ion must oe decomposed ata temperature below the decomposition temperature -of the resin used but above the elastomeric point of the resin composition. A layer oi resinous foam has heat insulating properties with the result that fusion of a prefoarned layer is very diflicuitand extremely slow. Therefore, in the case of compositions formulated with the preferred v-inyl chloride In vgeneralyainyl chloride polymer compositions attain kbody through partial gellation' when heatedto labout' 200 F; Thus, the minimum decomposition temper ature should be about 260 F. or higher.

The degree of foaming of a typical plastisol formulaof blowing agent is tien using dizierent concentrations shown in the following table:

the inventhe :N-N: antiv -N=i\`- linkage decompose at elevated temperatures to Parts Amfliiormnm- Ratio of tonni thick- Density, lhs. per cu. iue. per tot) parts resin ness tav-original thck- It.

, ness It. has been found that density of from about l2 tc 20 y pounds per cubic foot produces the most useful products.

The granules cr'chips'usually contain .fillers in addition to the other components.. Suitable.` llers include linzestone, asbestos, woodv flour, talc and. jthe li Typical formulations comprise about L20/io about 75% resin, about 101 to' abouti 30% pl'asicizer, about: 5 to about 7,5% ller ,including pigment, about 1 to about. 3% stabilizer andv about` 0.5 to about 5% lubricant. chips can. also' be formedv of a plastige composition ywhirl: becomes fused' uponsubseguentheating. Such compositionsare disclosed in US. Patent No. 3,015,640`

issuedV tnPetry and Weaver on Ianuary 2, 1962.

Y The granules are homogeneous particles containing all the ingredients of the. resin composition. They are conventionally prepared by mixing the various ingredients of resin, filler, pigments, a stabilizer and lubricant in a Banbury mixer at a temperature where the resin agences becomes solvated by the plasticizer and is soft enough to bind: all the ingredients together into a homogeneous mass, The mixing is usually carried out between '275 F. and 375 F., although the largest majority of com.- mercially available resins are usually mixed at about 290"- to 350 F. The homogeneous mass is then sheeteell between rolls and'lthesheet broken up to form the granules. The size of the granuli; can be varied depending on the typeot decoration to be produced. The granules can vary from tine particles having a size from about 0.02 to 0.96 in diameter up to granules having a vlargest dimension of one inch.' Even larger granules' can be utilized in combination with the smaller gran ules. The major portion of the granules, however,k

should be within the range of about 0.10 to about 0.50

inch in diameter. The thickness of the granules is pref` erably less than the thickness of thc sheet to he formed. The preferred thickness of the granules are from about 0.10 to about 0.015 inch. The granules should be at least one-half the thickness of finished sheet in order for the product to have adequate wearing qualities.

' Conventionally, the granules are formed from a sheet of uniform thickness so :hat all of the granules formed in this manner will have at least one uniformi dimension.

The tliickness of the liquid coating applied tothe web or release paper is critical in relation to the thickness of the granules distributed over iis surface in order to obtain a smooth sheet. It .should be understood, however, -that the granules orchips do not have to be completely embedded in the sheet. A textured surface is obtained if portionl of the granules extend above thev surface of the Ysheet from about (LOGI to about 0.005

inch. The liquid coating should have "l thickness less thanthe thickness of thegrunules. The thickness of -the coating, however, depends in large measure on the percentage of coverage of the coating by the granules. It is preferred to have the liquid coating less than twothirds the thickness of the granules ivi-tf1 less than onehalf the thickness vof the granules being particularly desirable.

The following examples are given for purposes of illustration; y f l EXAMFLE 1 l v Parts' Polyvmyl chloride (dispersion grade) 100 Di( thylhexyl) hexahydrophthalate 50 Epoxidizcd. soya oil 5 Wetting agent 2 Stabilizer 3 Pigment 3 The plastisol had a viscosity of 2,500 ccntipoises a vmeasured with a Brookfield RVF viscorneter using a No. 3 spindle at 2 r.p.m.

' EXAMPL: 2

The following ingredients in the proportions indicatedY were ground on a three-roll mill:

- Parfs polyvinyl chloride (dispersion grade) l0() Petroleum hydrocarbon condensate 1 i3 Butyl benzyl phthalate 37 'Pigrr nt p 3 Stabilizers s 4.

l'(Innoc 30G-Continental Oil Company. The plastisot was sut table, for seating,

l Exon Siti-Firestone Plastics Company. Pottstown', vIllu.

Relative viscosity of 2.65 (1% tn cyclohexanone).

Exon (iutk-Firestoney Plastics Co. Relative viscosity ot 2..,0 (1% in cyclohexnnonc).

- *Conoco H-SOO-Coutlncntal Gil Co., Ponca City, Okla.

The plnstisolwns suitable for coating. Y ff EXAMPLE 4 f v 1 A transparent organosol wasl prepared by 'mixing the following ingredients:

Vinyl chloride polymer (dispers'en grade) 100 Dioctyl phthalate 16 Tricresyl phosphate 8.5 Stabilizer 4.0 Mineral spirits The orgnnosol had a Brookfield viscosity. of 8,000 (2 r.p.m.-No. 3 spindle).`

EXAMPLE 5 A plastisol coating composition was prepared having the following composition:

VParts Polyvinyl chloride (dispersion grade) 100 Butyl benzyl phthalate 43.7 Alkyl aryl hydrocarbon 4.4 Barium-zinc complex 3.5

Titanium dioxide (58% uely divided TiOz ndioctyl phthalate) Hydrocarbon diluent- Stormer viscosity is seconds per 100 rev. at 77 P. under 200 gm. load.

EXAMPLE 6 A transparent organosol was prepared by mixing the following ingredients:

Parts Polyvmyl chloride (dispersion grade) y Dioctyl phthalate' 15 Trieresyl phosphate l5 Petroleum mineral spirits 20l Methylethyl ketone 2 Stabilizer i 5 EXAMPLE 7 A transparent organosol was prepared hy mixing the. following ingredients:

` Parts Polyvinyl chloride (dispersion grade) 100'I Dioczyl phthalate l0 Tricrcs-yl v phosphate 7 Epoxidized soya been oily 8.5 Barium-cadmium (stabilizer) Mineral spirits 215 Methyl ethyl ketone 2;

EYAMPLBS following ingredients on a conventional nhxeeroll mill:

NN- dimeihyi- NN einem@ ieimhaiamiae-f blowing agent mi. i ammira is y Tlie following-f ingredients in the proportions indicated were ground on a thrce-roll-mill:

Vinyl chloride-vinyl acetaie copolymer (dispersion-f 100 'polyvnyi cmo-ide (aspersin grade.) Palgr rade f A Y i Y I Dicgyi )phthalate 30. Petroleum hydrocarbon' eondensatel The plastisolhad a viscosity yof 16,800 eeniiposesat; 1Conocnsooa-coniineiifnion company.

smr; a Brookeld scomer "Bmg The nliistisol had a viscosity of 4,000 centipoises as measured with a Brookfield v-iscomeier using a No. 6

v Y EXAMPLE 9 Y spindle at 10 r.p.m.

The `following ingredients in the proportions indicated o0 n EXAMPLE' 14 were roundonathree-ro'lmill:

' g Y L paris f A oarnable plastisol was prepared having the follow- Polyvinyl chloride (dispersion grade) -'100 mgcompsmon P n Petroleum li drocrbon condensate1 18 v a S Buiyl benq-1y phihfla 52` Polyvinyl chloride (high molecular weight) 100A Pigment 3- 2 Polyvinyl chloride (low molecular wieght) -..l 100 Stabilizers y 4 A eodiformamide blowing argent 3 Azodiformaniide blowing agent 3.5- lflnll h g 1 Conoco SOO-Continental Cil Company, Ponen Ci'ry, Okla.l Bleryl 10o The plastisol had a viscosity of 4,000 centipoises as .The gaslssoll'd a BYOORCM Viscosity of 6,400 (2 measured with a Brookeld viscometer using E No. 6 r'p'm" o' Pm e') spindle ai 10 r.p.m.V v 1 EXAMPLE io l EXAMPLE 1,5

The following ingredients were ground on a* threemm :l5 o. size coat is Prepared having the following formularoll: Pans Parts n Polyvinyl chloride latexy (preplasiicized) 53 Potyvmyi Chlvvnde (dsperswn grade) 100 Carboxy vinyl polymer (iliickener 2% in water) 35 P eiroleum hydrocarbon condensatel 18 40 Wal-er 12 Butyl benzvi phthalate 52 Ammonatmisepmo 7 8. i Pigment 31v Stabilizers 4 C Azodiformamide blowing agent l *"XAMFLE 16 V' M' & P Bamba (bovdmg range 190450 F) 5' f5 A transparent plastisol of the following composition 1 comico sooncoiiiiiiciimi on company. Y was prepared? f I P ns a The .plastisol had a viscosity of 2,000 eenipoises as pqlyvmyfcmofide (dfpefson gmde) 1.00 measured with n Brookeld viiomeier using a No. 6V DI(fFhl/l-lexy')hxilyd1091111101211@v 50 spindle at 10 r.p.m. f 50 itldlled SOtya 011 f e ing agen EXAMPLE Stabilizer 3 i I. .Y i I I I moment 2 inch :ind varying in diameter from 0.02 to 0.50 inch were Wmng agen( 3 s evenly distributed on r-'liersurface of the werplastsol P coming to cover approximatcl 80% of the surface of N'gdlrgyl'NN Chmn-oso terephlhahmd blow' s 60. the sheet. vinyl composition Igranules had the fol- The iplastisol was vprepared. on a threeroll mill. .lowing omposmem i .l `pans i EXAMPLE 1.2 Polyvinyl chloride resin (viscosity 0.2") Q 25.4

. .Y Y Dipropylcne glycol dilbenzonie` 12.4

The Ifolico/ving ingredients in the propoi'iions indicated Slbllzer 1.5Y were ground on a 3roll mill: Y 51.62116 amd 1.0 Pans v P gment 1 0 ppiyvinyi chloride (dispersion grade; 100: Lmeslone 58' Didec l niithalaie 50 Didl dipa'te 25 70. The granules were prepared by mixing the ingredients sabiiizer 5 in a- Banbury mixer` at about 350 F. and then sheeting Pigment 2 the composition'. between heated calender rol-ls to forni av Welling agent 35 sri'eet 00110'v inch in thickness. The sheet was thea broken up into 'die granules and the granules mixed with similar granules ofeontiasiiegcoloration.

l 15 y The granuleecovered sheet was inverted to remove the' granules which did-.rmtV adhere to the liquid plastisol The sheet' was then passed through an oven heated at 400 F. with residence time in the oven of about 25.5 minutes. The

` heating caused the granules and coating to fuse into aA sub-` stantially homogeneous sheet. The hot sheet as it passed from` the' ovenl was subjected to av pla-nishingvoperationby passing betweenra smooth surface steel roll and a.

vrubber-coveredl resilient back-up roll'. The steel roll was` maintained at a temperature of about 200 F. and the rubber roll at less than' 150 F. The sheet. was carried in contact with the steel'- roll for most of one revolution of f the roll. lhev planished' sheet was then stript ed from theA release paper and' the surface in contact' with the release paper laminated to a foam-layer of 0.060 inch in thick-v ness" The foam layer was secured to an impregnated felt backing sheet. prepared by applyinga foamable composition coatingof 0.0l2 inch in thickness on the. surface of the feit sheet. The felt sheet was felled cellul'osic material 0.046 inch in thickness which had been impregnated with about of apolyvinyl acetate resin. The foarnable composition had thevfollowing formulation:

Parts Vinyl chloride-vinyl acetate polymer 00 Dioctyl phthalate .v 3G Dipropylcne glycol dibenzoate Stabilizer 6 Azodiiormamide blowing agent 2.5

l The foamahle composition l-was coated on the surface of the felt sheet to the thickness lindicated and then passed into an oven heated at 400 F. to fuse the composition and decompose the blowing agent to toam the layer. The residence time in thc oven was three minutes.

The laminated product had a smooth surface containing the decorative granules and an interlayer of foam which gave the product excellent resiliency.

EXAMPLE 17 The general method of Example 16 was followed except that the foamahle composition was coated directly on the vinyl composition coating on the release paper prior to fusing the coating composition, but after heating at'400" F. for 'one minute to gel the coating. The sheet was then passedthrough the oven in the same manner as described to decompose the blowing agent and fuse the compositions in both coating compositions. The product is then cooled and the foam surface is laminated to a flooring felt impregnated with asphalt with an adhesive.k The adhesive comprised a mixture of b'ma rubber and 50% wood resin (softening point 234 F.-239F.). The procedure used for amination was that disclosed in U.S. Patent 2,757,711V issued Aug. 7, i956 to Petry, ci al. After lamination of the felt the release paper was stripped from the, surface of the product. The'resnlting laminate was similar to the product in Example 16 except that the surface was very smooth and on a dull sheen.

EXAMPLE 18 An asbestos feit sheet of 0.055 inch in thickness and impregnated with about l5% of a butadiene-acrylonitrile copolymer vwas coated on one surface with the following adhesive: l 'a l Parts Plasticized acrylic resin (46% solids) 53 Clay filler 47 the adhesive coating was about 0.001` inca in micrness. Granules of vinyl composition were prepared as in Example t6 having a thickness 060.020 inch and a square configuration of about 0.25 inchvneach surface dimension. 'Die square granules were` rdistributed on the ad- The foaabcovered feltsheet has been hesivecoated surface of the felt in alayer of apprenti` mately one chip thickness. The. feltsheet was vibrated to form the single layer. Approximatelyof` the sur face ot' the sheet was covered'- with chips. The` chipcovered sheet was then hcatedvtoftackifythe adhesive andy' passed through prcss'ingrolls to secure thev chips to the e-dlv-:siv i A vinyl :omposi the composition of lthe coating and chips together into a substantially homogeneoussheet. The release paper wasl then removed and' the product was ready for usel as adecorative surface covering. n

Any departure from the forcgoing descriptionl whichv conforms to the invention is intended to be included within the scope of the claims. l

What is claimed is:

1. A process for producing a decorative' surface covering having a continuous solid surfacey which comprises applying a liquid vinyl chloride polymer composition to the surface of a release paper, depositing on the liquid coating decorative granules of vinyl composition having a thickness greater than the kthickness of said liquid coat.k ing to cover about tt) to about 90% of the coating, heating to partially fuse the coating, applying a foamable vinyl `composition containing a blowing agent'to the sur face of the partially fused coating, heating to fusethe compositions and decompose the blowing agent and convert the foamable composition to a cellular foam layer, cooling the product thus formed and then stripping the release paper from its surface.

2. The process of claim 1 wherein said partially fused coating is subjected to a planisiting operation without substantiallyreducing the temperature of the sheet below its fusion temperature by passing between a hard surface roll and a rubber covered roll.

3. The process of claim 1 wherein. said liquid coatingV has -a thieness of less than about two-thirds the thick ness of said granules.

4. The process cf claim 1 wherein said granules have` a thickness of about 0.10 to about 0.50 inch and are allof substantially uniform thickness.

5. A process for producing a decorative surface coverv ing` having a continuous solid surface which comprises ap,-

plying a liquid vinyl chloride polymer composition coat ing to the surface of a release paper, depositing on the liquid coating decorative granules of vinyl' composition having a thickness greater than the thickness of said" liquid coating to :over about t0 to' about 9 l%.of the coating, heating to partially fuse the coating, applying a foama'c-'ae vinyl composition containing a blowing agent to the surface of a backing web. heating the foamable composition to partially fuse the composition without decomposing the blowingt agent. laminatingl the surface of the .v

partially fused foamed compositionto the surface of the partially fused coating containing the granules and there'- aftcr heating to fuse the compositions and decompose thev blowing agent to convert the foamable compositionrto a cellulose toam 133er, stripping the release paper from lthe composite laminate. and their cooling the product thus; formed.

6. The process of claim 5 wherein said liquid coating has a thickness of less than. about two-thirds the, thiclc Y ness of the granules, the thickness of the granulesis about 0.10 to 0.5.0 inch and all o the granules' have a substantially uniform thickness. i

7. The process o fused coating is subiected to a plamslzng operation without' substantially reducing the-temperature of, the sheet helolltV claim s wherein sad penalty,V

l l l 'l i v szm its fusion tcrperamie by pafssigbefwecn a hard surface f 12.888.975 61H59 Benedict 'Y 2,894,855- ?!1959' Wilhelm et a1.

roll and a rubber-covered,

l Y l 2,983,962 5-/1961 NGIZ Ct al. 15G-79 Refrences C'ted by the Examiner v 35.332328 5/1962 Beule el alv' 15678 UNITED STATES PATENTS j v EARL M. BERGERT, Primary Examiner. 2,213,909 10/1940 Gm Q- lllf'-- HAROLD ANSHER Exwniner 2,"68,787' 2/1954 ShlB-mm 117-"4 9 2,;13'052 1K2 M957. mster. v. A. MALLARE, T. RSM/0,113, .4mm Examiners. 

5. A PROCESS FOR PRODUCING A DECORATIVE SURFACE COVERING HAVING A CONTINUOUS SOLID SURFACE WHICH COMPRISES APPLYING A LIQUID VINYL CHLORIDE POLYMER COMPOSITION COATING TO THE SURFACE OF A RELEASE PAPER, DEPOSITING ON THE LIQUID COATING DECORATIVE GRANULES OF VINYL COMPOSITION HAVING A THICKNESS GREATER THAN THE THICKNESS OF SAID LIQUID COATING TO COVER ABOUT 10 TO ABOUT 90% OF THE COATING, HEATING TO PARTIALLY FUSE THE COATING, APPLYING A FOAMABLE VINYL COMPOSITION CONTAINING A BLOWING AGENT TO THE SURFACE OF A BACKING WEB, HEATING THE FOAMABLE COMPOSITION TO PARTIALLY FUSE THE COMPOSITON WITHOUT DECOMPOSING THE BLOWING AGENT, LAMINATING THE SURFACE OF THE PARTIALLY FUSED FOAMED COMPOSITION TO THE SURFACE OF THE PARTIALLY FUSED COATING CONTAINING THE GRANULES AND THEREAFTER HEATING TO FUSE THE COMPOSITIONS AND DECOMPOSE THE BLOWING AGENT TO CONVERT THE FOAMABLE COMPOSITION TO A CELLULOSE FOAM LAYER, STRIPPING THE RELEASE PAPER FROM THE COMPOSITE LAMINATE AND THEN COOLING THE PRODUCT THUS FORMED. 